Robotic multi-gripper assemblies and methods for gripping and holding objects

ABSTRACT

A method for operating a transport robot includes receiving image data representative of a group of objects. One or more target objects are identified in the group based on the received image data. Addressable vacuum regions are selected based on the identified one or more target objects. The transport robot is command to cause the selected addressable vacuum regions to hold and transport the identified one or more target objects. The transport robot includes a multi-gripper assembly having an array of addressable vacuum regions each configured to independently provide a vacuum. A vision sensor device can capture the image data, which is representative of the target objects adjacent to or held by the multi-gripper assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/855,751 filed Apr. 22, 2020, now allowed, which claims the benefit ofU.S. Provisional Patent Application No. 62/889,562 filed Aug. 21, 2019,both of which are incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present technology is directed generally to robotic systems and,more specifically, robotic multi-grippers assemblies configured toselectively grip and hold objects.

BACKGROUND

Robots (e.g., machines configured to automatically/autonomously executephysical actions) are now extensively used in many fields. Robots, forexample, can be used to execute various tasks (e.g., manipulate ortransfer an object) in manufacturing, packaging, transport and/orshipping, etc. In executing the tasks, robots can replicate humanactions, thereby replacing or reducing human involvements that areotherwise required to perform dangerous or repetitive tasks. Robotsoften lack the sophistication necessary to duplicate human sensitivityand/or adaptability required for executing more complex tasks. Forexample, robots often have difficulty selectively gripping object(s)from a group of objects with immediately neighboring objects, as well asirregular shaped/sized objects, etc. Accordingly, there remains a needfor improved robotic systems and techniques for controlling and managingvarious aspects of the robots.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of an example environment in which a roboticsystem transports objects in accordance with one or more embodiments ofthe present technology.

FIG. 2 is a block diagram illustrating the robotic system in accordancewith one or more embodiments of the present technology.

FIG. 3 illustrates a multi-component transfer assembly in accordancewith one or more embodiments of the present technology.

FIG. 4 is a front view of an end effector coupled to a robotic arm of atransport robot in accordance with one or more embodiments of thepresent technology.

FIG. 5 is a bottom view of the end effector of FIG. 4.

FIG. 6 is a functional block diagram of a robotic transfer assembly inaccordance with one or more embodiments of the present technology.

FIG. 7 is a front, top isometric view of an end effector with amulti-gripper assembly in accordance with one or more embodiments of thepresent technology.

FIG. 8 is a front, bottom isometric view of the end effector of FIG. 7.

FIG. 9 is an exploded front isometric view of components of a vacuumgripper assembly with one or more embodiments of the present technology.

FIG. 10 is an isometric view of an assembly of vacuum grippers inaccordance with one or more embodiments of the present technology.

FIG. 11 is a top plan view of the assembly of FIG. 10.

FIG. 12 is an isometric view of an assembly of vacuum grippers inaccordance with one or more embodiments of the present technology.

FIG. 13 is an isometric view of a multi-gripper assembly in accordancewith another embodiment of the present technology.

FIG. 14 is an exploded isometric view of the multi-gripper assembly ofFIG. 13.

FIG. 15 is a partial cross-sectional view of a portion of amulti-gripper assembly in accordance with one or more embodiments of thepresent technology.

FIG. 16 is a flow diagram for operating a robotic system in accordancewith some embodiments of the present technology.

FIG. 17 is another flow diagram for operating a robotic system inaccordance with one or more embodiments of the present technology.

FIGS. 18-21 illustrate stages of robotically gripping and transportingobjects in accordance with one or more embodiments of the presenttechnology.

DETAILED DESCRIPTION

Systems and methods for gripping selected objects are described herein.The systems can include a transport robot with multi-gripper assembliesconfigured to be operated independently or in conjunction togrip/release a single object or a plurality of objects. For example, thesystems can pick up multiple objects at the same time or sequentially.The system can select objects to be carried based upon, for example, thecarrying capability of the multi-gripper assembly, a transport plan, orcombinations thereof. The multi-gripper assembly can reliably gripobjects from a group of objects, irregular objects, shaped/sizedobjects, etc. For example, the multi-gripper assemblies can includeaddressable vacuum regions or banks each configured to draw in air suchthat only selected objects are held via a vacuum grip. The multi-gripperassembly can be robotically moved to transport the retained objects to adesired location and can then release the objects. The system can alsorelease gripped objects at the same time or sequentially. This processcan be repeated to transport any number of objects between differentlocations.

At least some embodiments are directed to a method for operating atransport robot having a multi-gripper assembly with addressable pick-upregions. The pick-up regions can be configured to independently providevacuum gripping. Target object(s) are identified based on captured imagedata. The pick-up regions can draw in air to grip the identified targetobject(s). In some embodiments, a transport robot to robotically movethe multi-gripper assembly, which is carrying the identified targetobjects.

In some embodiments, a robotic transport system includes a roboticapparatus, a target object detector, and a vacuum gripper device. Thevacuum gripper device includes a plurality of addressable regions and amanifold assembly. The manifold assembly can be fluidically coupled toeach of the addressable regions and to at least one vacuum line suchthat each addressable region is capable of independently providing anegative pressure via an array of suction elements. The negativepressure can be sufficient to hold at least one target object againstthe vacuum gripper device while the robotic apparatus moves the vacuumgripper device between different locations.

A method for operating a transport robot includes receiving image datarepresentative of a group of objects (e.g., a stack or pile of objects).One or more target objects are identified in the group based on thereceived image data. Addressable vacuum regions are selected based onthe identified one or more target objects. The transport robot iscommand to cause the selected vacuum regions to hold and transport theidentified one or more target objects. The transport robot includes amulti-gripper assembly having an array of vacuum regions each configuredto independently provide vacuum gripping. A vision sensor device cancapture the image data, which is representative of the target objectsadjacent to or held by the vacuum gripper device

In the following, numerous specific details are set forth to provide athorough understanding of the presently disclosed technology. In otherembodiments, the techniques introduced here can be practiced withoutthese specific details. In other instances, well-known features, such asspecific functions or routines, are not described in detail in order toavoid unnecessarily obscuring the present disclosure. References in thisdescription to “an embodiment,” “one embodiment,” or the like mean thata particular feature, structure, material, or characteristic beingdescribed is included in at least one embodiment of the presentdisclosure. Thus, the appearances of such phrases in this specificationdo not necessarily all refer to the same embodiment. On the other hand,such references are not necessarily mutually exclusive either.Furthermore, the particular features, structures, materials, orcharacteristics can be combined in any suitable manner in one or moreembodiments. It is to be understood that the various embodiments shownin the figures are merely illustrative representations and are notnecessarily drawn to scale.

Several details describing structures or processes that are well-knownand often associated with robotic systems and subsystems, but that canunnecessarily obscure some significant aspects of the disclosedtechniques, are not set forth in the following description for purposesof clarity. Moreover, although the following disclosure sets forthseveral embodiments of different aspects of the present technology,several other embodiments can have different configurations or differentcomponents than those described in this section. Accordingly, thedisclosed techniques can have other embodiments with additional elementsor without several of the elements described below.

Many embodiments or aspects of the present disclosure described belowcan take the form of computer- or controller-executable instructions,including routines executed by a programmable computer or controller.Those skilled in the relevant art will appreciate that the disclosedtechniques can be practiced on computer or controller systems other thanthose shown and described below. The techniques described herein can beembodied in a special-purpose computer or data processor that isspecifically programmed, configured, or constructed to execute one ormore of the computer-executable instructions described below.Accordingly, the terms “computer” and “controller” as generally usedherein refer to any data processor and can include Internet appliancesand handheld devices (including palm-top computers, wearable computers,cellular or mobile phones, multi-processor systems, processor-based orprogrammable consumer electronics, network computers, mini computers,and the like). Information handled by these computers and controllerscan be presented at any suitable display medium, including a liquidcrystal display (LCD). Instructions for executing computer- orcontroller-executable tasks can be stored in or on any suitablecomputer-readable medium, including hardware, firmware, or a combinationof hardware and firmware. Instructions can be contained in any suitablememory device, including, for example, a flash drive, USB device, and/orother suitable medium, including a tangible, non-transientcomputer-readable medium.

The terms “coupled” and “connected,” along with their derivatives, canbe used herein to describe structural relationships between components.It should be understood that these terms are not intended as synonymsfor each other. Rather, in particular embodiments, “connected” can beused to indicate that two or more elements are in direct contact witheach other. Unless otherwise made apparent in the context, the term“coupled” can be used to indicate that two or more elements are ineither direct or indirect (with other intervening elements between them)contact with each other, or that the two or more elements co-operate orinteract with each other (e.g., as in a cause-and-effect relationship,such as for signal transmission/reception or for function calls), orboth.

Suitable Environments

FIG. 1 is an illustration of an example environment in which a roboticsystem 100 transports objects. The robotic system 100 can include anunloading unit 102, a transfer unit or assembly 104 (“transfer assembly104”), a transport unit 106, a loading unit 108, or a combinationthereof in a warehouse or a distribution/shipping hub. Each of the unitsof the robotic system 100 can be configured to execute one or moretasks. The tasks can be combined in sequence to perform an operationthat achieves a goal, such as to unload objects from a truck or a vanfor storage in a warehouse or to unload objects from storage locationsand load them onto a truck or a van for shipping. In another example,the task can include moving objects from one container to anothercontainer. Each of the units can be configured to execute a sequence ofactions (e.g., operating one or more components therein) to execute atask.

In some embodiments, the task can include manipulation (e.g., movingand/or reorienting) of a target object or package 112 (e.g., boxes,cases, cages, pallets, etc.) from a start location 114 to a tasklocation 116. For example, the unloading unit 102 (e.g., a devanningrobot) can be configured to transfer the target package 112 from alocation in a carrier (e.g., a truck) to a location on a conveyor belt.The transfer assembly 104 (e.g., a palletizing robot assembly) can beconfigured to load packages 112 onto the transport unit 106 or conveyor120. In another example, the transfer assembly 104 can be configured totransfer one or more target packages 112 from one container to anothercontainer. The transfer assembly 104 can include a robotic end effector140 (“end effector 140”) with vacuum grippers (or vacuum regions) eachindividually operated to pick up and carry object(s) 112. When the endeffector 140 is placed adjacent an object, air can be into thegripper(s) adjacent to target packages 112, thereby creating a pressuredifferential sufficient for retaining the target objects. The targetobjects can be picked up and transported without damaging or marring theobject surfaces. The number of packages 112 carried at one time can beselected based upon stacking arrangements of objects at the pick-uplocation, available space at the drop off location, transport pathsbetween pick-up and drop off locations, optimization routines (e.g.,routines for optimizing unit usage, robotic usage, etc.), combinationsthereof, or the like. The end effector 140 can have one or more sensorsconfigured to output readings indicating information about retainedobjects (e.g., number and configurations of retained objects), relativepositions between any retained objects, or the like.

An imaging system 160 can provide image data used to monitor operationof components, identify target objects, track objects, or otherwiseperform tasks. The image data can be analyzed to evaluate, for example,package stacking arrangements (e.g., stacked packages, such as cardboardboxes, packing containers, etc.), positional information of objects,available transport paths (e.g., transport paths between pickup zonesand drop off zones), positional information about gripping assemblies,or combinations thereof. A controller 109 can communicate with theimaging system 160 and other components of the robotic system 100. Thecontroller 109 can generate transport plans that include a sequence forpicking up and dropping off objects (e.g., illustrated as stablecontainers), positioning information, order information for picking upobjects, order information for dropping off objects, stacking plans(e.g., plans for stacking objects at the drop off zone), re-stackingplans (e.g., plans for re-stacking at least some of the containers atthe pickup zone), or combinations thereof. The information andinstructions provided by transport plans can be selected based on thearrangement of the containers, the contents of the containers, orcombinations thereof. In some embodiments, the controller 109 caninclude electronic/electrical devices, such as one or more processingunits, processors, storage devices (e.g., external or internal storagedevices, memory, etc.), communication devices (e.g., communicationdevices for wireless or wired connections), and input-output devices(e.g., screens, touchscreen displays, keyboards, keypads, etc.). Exampleelectronic/electrical devices and controller components are discussed inconnection with FIGS. 2 and 6.

The transport unit 106 can transfer the target package 112 (or multipletarget packages 112) from an area associated with the transfer assembly104 to an area associated with the loading unit 108, and the loadingunit 108 can transfer the target package 112 (by, e.g., moving thepallet carrying the target package 112) to a storage location. In someembodiments, the controller 109 can coordinate operation of the transferassembly 104 and the transport unit 106 to efficiently load objects ontostorage shelves.

The robotic system 100 can include other units, such as manipulators,service robots, modular robots, etc., not shown in FIG. 1. For example,in some embodiments, the robotic system 100 can include a de-palletizingunit for transferring the objects from cage carts or pallets ontoconveyors or other pallets, a container-switching unit for transferringthe objects from one container to another, a packaging unit for wrappingthe objects, a sorting unit for grouping objects according to one ormore characteristics thereof, a piece-picking unit for manipulating(e.g., for sorting, grouping, and/or transferring) the objectsdifferently according to one or more characteristics thereof, or acombination thereof. Components and subsystems of the system 100 caninclude different types of and effectors. For example, unloading unit102, transport unit 106, loading unit 108, and other components of therobotic system 100 can also include robotic multi-gripper assemblies.The configurations of the robotic gripper assemblies can be selectedbased on desired carrying capabilities. For illustrative purposes, therobotic system 100 is described in the context of a shipping center;however, it is understood that the robotic system 100 can be configuredto execute tasks in other environments/purposes, such as formanufacturing, assembly, packaging, healthcare, and/or other types ofautomation. Details regarding the task and the associated actions aredescribed below.

Robotic Systems

FIG. 2 is a block diagram illustrating components of the robotic system100 in accordance with one or more embodiments of the presenttechnology. In some embodiments, for example, the robotic system 100(e.g., at one or more of the units or assemblies and/or robots describedabove) can include electronic/electrical devices, such as one or moreprocessors 202, one or more storage devices 204, one or morecommunication devices 206, one or more input-output devices 208, one ormore actuation devices 212, one or more transport motors 214, one ormore sensors 216, or a combination thereof. The various devices can becoupled to each other via wire connections and/or wireless connections.For example, the robotic system 100 can include a bus, such as a systembus, a Peripheral Component Interconnect (PCI) bus or PCI-Express bus, aHyperTransport or industry standard architecture (ISA) bus, a smallcomputer system interface (SCSI) bus, a universal serial bus (USB), anIIC (I2C) bus, or an Institute of Electrical and Electronics Engineers(IEEE) standard 1394 bus (also referred to as “Firewire”). Also, forexample, the robotic system 100 can include bridges, adapters,controllers, or other signal-related devices for providing the wireconnections between the devices. The wireless connections can be basedon, for example, cellular communication protocols (e.g., 3G, 4G, LTE,5G, etc.), wireless local area network (LAN) protocols (e.g., wirelessfidelity (WIFI)), peer-to-peer or device-to-device communicationprotocols (e.g., Bluetooth, Near-Field communication (NFC), etc.),Internet of Things (IoT) protocols (e.g., NB-IoT, Zigbee, Z-wave, LTE-M,etc.), and/or other wireless communication protocols.

The processors 202 can include data processors (e.g., central processingunits (CPUs), special-purpose computers, and/or onboard servers)configured to execute instructions (e.g., software instructions) storedon the storage devices 204 (e.g., computer memory). The processors 202can implement the program instructions to control/interface with otherdevices, thereby causing the robotic system 100 to execute actions,tasks, and/or operations.

The storage devices 204 can include non-transitory computer-readablemediums having stored thereon program instructions (e.g., software).Some examples of the storage devices 204 can include volatile memory(e.g., cache and/or random-access memory (RAM) and/or non-volatilememory (e.g., flash memory and/or magnetic disk drives). Other examplesof the storage devices 204 can include portable memory drives and/orcloud storage devices.

In some embodiments, the storage devices 204 can be used to furtherstore and provide access to master data, processing results, and/orpredetermined data/thresholds. For example, the storage devices 204 canstore master data that includes descriptions of objects (e.g., boxes,cases, containers, and/or products) that may be manipulated by therobotic system 100. In one or more embodiments, the master data caninclude a dimension, a shape (e.g., templates for potential poses and/orcomputer-generated models for recognizing the object in differentposes), mass/weight information, a color scheme, an image,identification information (e.g., bar codes, quick response (QR) codes,logos, etc., and/or expected locations thereof), an expected mass orweight, or a combination thereof for the objects expected to bemanipulated by the robotic system 100. In some embodiments, the masterdata can include manipulation-related information regarding the objects,such as a center-of-mass location on each of the objects, expectedsensor measurements (e.g., force, torque, pressure, and/or contactmeasurements) corresponding to one or more actions/maneuvers, or acombination thereof. The robotic system can look up pressure levels(e.g., vacuum levels, suction levels, etc.), gripping/pickup areas(e.g., areas or banks of vacuum grippers to be activated), and otherstored master data for controlling transfer robots. The storage devices204 can also store object tracking data. In some embodiments, the objecttracking data can include a log of scanned or manipulated objects. Insome embodiments, the object tracking data can include image data (e.g.,a picture, point cloud, live video feed, etc.) of the objects at one ormore locations (e.g., designated pickup or drop locations and/orconveyor belts). In some embodiments, the object tracking data caninclude locations and/or orientations of the objects at the one or morelocations.

The communication devices 206 can include circuits configured tocommunicate with external or remote devices via a network. For example,the communication devices 206 can include receivers, transmitters,modulators/demodulators (modems), signal detectors, signalencoders/decoders, connector ports, network cards, etc. Thecommunication devices 206 can be configured to send, receive, and/orprocess electrical signals according to one or more communicationprotocols (e.g., the Internet Protocol (IP), wireless communicationprotocols, etc.). In some embodiments, the robotic system 100 can usethe communication devices 206 to exchange information between units ofthe robotic system 100 and/or exchange information (e.g., for reporting,data gathering, analyzing, and/or troubleshooting purposes) with systemsor devices external to the robotic system 100.

The input-output devices 208 can include user interface devicesconfigured to communicate information to and/or receive information fromhuman operators. For example, the input-output devices 208 can include adisplay 210 and/or other output devices (e.g., a speaker, a hapticscircuit, or a tactile feedback device, etc.) for communicatinginformation to the human operator. Also, the input-output devices 208can include control or receiving devices, such as a keyboard, a mouse, atouchscreen, a microphone, a user interface (UI) sensor (e.g., a camerafor receiving motion commands), a wearable input device, etc. In someembodiments, the robotic system 100 can use the input-output devices 208to interact with the human operators in executing an action, a task, anoperation, or a combination thereof.

In some embodiments, a controller (e.g., controller 109 of FIG. 1) caninclude the processors 202, storage devices 204, communication devices206, and/or input-output devices 208. The controller can be a standalonecomponent or part of a unit/assembly. For example, each unloading unit,a transfer assembly, a transport unit, and a loading unit of the system100 can include one or more controllers. In some embodiments, a singlecontroller can control multiple units or standalone components.

The robotic system 100 can include physical or structural members (e.g.,robotic manipulator arms) connected at joints for motion (e.g.,rotational and/or translational displacements). The structural membersand the joints can form a kinetic chain configured to manipulate anend-effector (e.g., the gripper) configured to execute one or more tasks(e.g., gripping, spinning, welding, etc.) depending on the use/operationof the robotic system 100. The robotic system 100 can include theactuation devices 212 (e.g., motors, actuators, wires, artificialmuscles, electroactive polymers, etc.) configured to drive or manipulate(e.g., displace and/or reorient) the structural members about or at acorresponding joint. In some embodiments, the robotic system 100 caninclude the transport motors 214 configured to transport thecorresponding units/chassis from place to place. For example, theactuation devices 212 and transport motors connected to or part of arobotic arm, a linear slide, or other robotic component.

The sensors 216 can be configured to obtain information used toimplement the tasks, such as for manipulating the structural membersand/or for transporting the robotic units. The sensors 216 can includedevices configured to detect or measure one or more physical propertiesof the robotic system 100 (e.g., a state, a condition, and/or a locationof one or more structural members/joints thereof) and/or for asurrounding environment. Some examples of the sensors 216 can includecontact sensors, proximity sensors, accelerometers, gyroscopes, forcesensors, strain gauges, torque sensors, position encoders, pressuresensors, vacuum sensors, etc.

In some embodiments, for example, the sensors 216 can include one ormore imaging devices 222 (e.g., 2-dimensional and/or 3-dimensionalimaging devices). configured to detect the surrounding environment. Theimaging devices can include cameras (including visual and/or infraredcameras), lidar devices, radar devices, and/or other distance-measuringor detecting devices. The imaging devices 222 can generate arepresentation of the detected environment, such as a digital imageand/or a point cloud, used for implementing machine/computer vision(e.g., for automatic inspection, robot guidance, or other roboticapplications).

Referring now to FIGS. 1 and 2, the robotic system 100 (via, e.g., theprocessors 202) can process image data and/or the point cloud toidentify the target package 112 of FIG. 1, the start location 114 ofFIG. 1, the task location 116 of FIG. 1, a pose of the target package112 of FIG. 1, or a combination thereof. The robotic system 100 can useimage data to determine how to access and pick up objects. Images of theobjects can be analyzed to determine a pickup plan for positioning avacuum gripper assembly to grip targeted objects even though adjacentobjects may also be proximate to the gripper assembly. Imaging outputfrom onboard sensors 216 (e.g., lidar devices) and image data fromremote devices (e.g., the imaging system 160 of FIG. 1) can be utilizedalone or in combination. The robotic system 100 (e.g., via the variousunits) can capture and analyze an image of a designated area (e.g.,inside the truck, inside the container, or a pickup location for objectson the conveyor belt) to identify the target package 112 and the startlocation 114 thereof. Similarly, the robotic system 100 can capture andanalyze an image of another designated area (e.g., a drop location forplacing objects on the conveyor belt, a location for placing objectsinside the container, or a location on the pallet for stacking purposes)to identify the task location 116.

Also, for example, the sensors 216 of FIG. 2 can include positionsensors 224 FIG. 2 (e.g., position encoders, potentiometers, etc.)configured to detect positions of structural members (e.g., the roboticarms and/or the end-effectors) and/or corresponding joints of therobotic system 100. The robotic system 100 can use the position sensors224 to track locations and/or orientations of the structural membersand/or the joints during execution of the task. The unloading unit,transfer unit, transport unit/assembly, and the loading unit disclosedherein can include the sensors 216.

In some embodiments, the sensors 216 can include contact sensors 226(e.g., force sensors, strain gauges, piezoresistive/piezoelectricsensors, capacitive sensors, elastoresistive sensors, and/or othertactile sensors) configured to measure a characteristic associated witha direct contact between multiple physical structures or surfaces. Thecontact sensors 226 can measure the characteristic that corresponds to agrip of the end-effector (e.g., the gripper) on the target package 112.Accordingly, the contact sensors 226 can output a contact measurementthat represents a quantified measurement (e.g., a measured force,torque, position, etc.) corresponding to physical contact, a degree ofcontact or attachment between the gripper and the target package 112, orother contact characteristics. For example, the contact measurement caninclude one or more force, pressure, or torque readings associated withforces associated with gripping the target package 112 by theend-effector. In some embodiments, the contact measurement can includeboth (1) pressure readings associated with vacuum gripping and (2) forcereadings (e.g., moment readings) associated with carrying object(s).Details regarding the contact measurements are described below.

As described in further detail below, the robotic system 100 (via, e.g.,the processors 202) can implement different actions to accomplish tasksbased on the contact measurement, image data, combinations thereof, etc.For example, the robotic system 100 can regrip the target package 112 ifthe initial contact measurement is below a threshold, such as the vacuumgrip is low (e.g., a suction level is below a vacuum threshold), orcombinations thereof. Also, the robotic system 100 can intentionallydrop the target package 112, adjust the task location 116, adjust aspeed or an acceleration for the action, or a combination thereof basedon one or more transport rules (e.g., if the contact measure or suctionlevel falls below a threshold during execution of the task) and thecontact measurements, image data, and/or other readings or data.

Robotic Transfer Assembly

FIG. 3 illustrates the transfer assembly 104 in accordance with one ormore embodiments of the present technology. The transfer assembly 104can include the imaging system 160 and a robotic arm system 132. Theimaging system 160 can provide image data captured from a targetenvironment with a de-palletizing platform 110. The robotic arm system132 can include a robotic arm assembly 139 and an end effector 140,which includes a vision sensor device 143 and a multi-gripper assembly141 (“gripper assembly 141”). The robotic arm assembly 139 can positionthe end effector 140 above a group of objects in a stack 165 located ata pickup environment 163. The vision sensor device 143 can detect nearbyobjects without contacting, moving, or dislodging objects in the stack165.

Target objects can be secured against the bottom of the end effector140. In some embodiments, the gripper assembly 141 can have addressableregions each selectively capable of drawing in air for providing avacuum grip. In some modes of operation, only addressable regionsproximate to the targeted object(s) draw in air to provide a pressuredifferential directly between the vacuum gripper device and the targetedobject(s). This allows only selected packages (i.e., targeted packages)to be pulled or otherwise secured against the gripper assembly 141 eventhough other gripping portions of the gripper assembly 141 are adjacentto or contact other packages.

FIG. 3 shows the gripper assembly 141 carrying a single object orpackage 112 (“package 112”) positioned above a conveyer 120. The gripperassembly 141 can release the package 112 onto a conveyor belt 120, andthe robotic arm system 132 can then retrieve the packages 112 a, 112 bby positioning the unloaded gripper assembly 141 directly above bothpackages 112 a, 112 b. The gripper assembly 141 can then hold, via avacuum grip, both packages 112 a, 112 b, and the robotic arm system 132can carry the retained packages 112 a, 112 b to a position directlyabove the conveyor 120. The gripper assembly 141 can then release (e.g.,simultaneous or sequentially) the packages 112 a, 112 b onto theconveyor 120. This process can be repeated any number of times to carrythe objects from the stack 165 to the conveyor 120.

The vision sensor device 143 can include one or more optical sensorsconfigured to detect packages held underneath the gripper assembly 141.The vision sensor device 143 can be positioned to the side of thegripper assembly 141 to avoid interference with package pick up/dropoff. In some embodiments, the vision sensor device 143 is movablycoupled to the end effector 140 or robotic arm 139 such that the visionsensor device 143 can be moved to different sides of the gripperassembly 141 to avoid striking objects while detecting a presence of oneor more objects, if any, held by the gripper assembly 141. The position,number, and configurations of the vision sensor devices 143 can beselected based on the configuration of the gripper assembly 141.

With continued reference to FIG. 3, the de-palletizing platform 110 caninclude any platform, surface, and/or structure upon which a pluralityof objects or packages 112 (singularly, “package 112”) may be stackedand/or staged and ready to be transported. The imaging system 160 caninclude one or more imaging devices 161 configured to capture image dataof the packages 112 on the de-palletizing platform 110. The imagingdevices 161 can capture distance data, position data, video, stillimages, lidar data, radar data and/or motion at the pickup environmentor region 163. It should be noted that, although the terms “object” and“package” are used herein, the terms include any other items capable ofbeing gripped, lifted, transported, and delivered such as, but notlimited to, “case,” “box”, “carton,” or any combination thereof.Moreover, although polygonal boxes (e.g., rectangular boxes) areillustrated in the drawings disclosed herein, the shapes of the boxesare not limited to such shape but includes any regular or irregularshape that, as discussed in detail below, is capable of being gripped,lifted, transported, and delivered.

Like the de-palletizing platform 110, the receiving conveyor 120 caninclude any platform, surface, and/or structure designated to receivethe packages 112 for further tasks/operations. In some embodiments, thereceiving conveyor 120 can include a conveyor system for transportingthe package 112 from one location (e.g., a release point) to anotherlocation for further operations (e.g., sorting and/or storage).

FIG. 4 is a front view of the end effector 140 coupled to the roboticarm 139 in accordance with some embodiments of the present technology.FIG. 5 is a bottom view of the end effector 140 of FIG. 4. The visionsensor device 143 can include one or more sensors 145 configured todetect packages and a calibration board 147 used to, for example,calibrate the position of the gripper assembly 141 relative to thevision sensor device 143. In some embodiments, the calibration board 147can be a placard with a pattern or design used for calibrating ordefining the position of the end effector 140 or gripper assembly 141within the operating environment, position of the robotic arm 139, or acombination thereof. The gripper assembly 141 can include addressablevacuum zones or regions 117 a, 117 b, 117 c (collectively “vacuumregions 117”) defining a gripping zone 125. The description of onevacuum region 117 applies to the other vacuum regions 117 unlessindicated otherwise. In some embodiments, each vacuum region 117 can bea suction channel bank that includes components connected to a vacuumsource external to the end effector 140. The vacuum regions 117 caninclude gripping interfaces 121 (one identified in FIG. 4) against whichobjects can be held.

Referring now to FIG. 4, the vacuum region 117 a can draw in air to holdthe package 112 and can reduce or stop drawing in air to release thepackage 112. The vacuum regions 117 b, 117 c (illustrated not holdingpackages) can independently draw in air (indicated by arrows) to holdpackages at corresponding positions 113 a, 113 b (illustrated in phantomline in FIG. 4). Referring now to FIG. 5, the vacuum regions 117 caninclude a group or bank of suction elements 151 (one identified in FIG.5) through which air is drawn. The suction elements 151 can beevenly/uniformly or unevenly spaced apart from one another and can bearranged in a desired pattern (e.g., an irregular or regular pattern).The vacuum regions 117 can have the same or different number,configurations, and/or pattern of suction elements 151. To carry apackage that matches the geometry of the vacuum region 117, air can bedrawn through each suction element 151 of the vacuum region 117. Tocarry smaller packages, air can be drawn through a subset of the suctionelements 151 matching the geometry of the package (e.g., suctionelements 151 positioned within the boundary or perimeter of thepackage). For example, air can be drawn through a subset of the suctionelements for one of the vacuum region 117, such as only the suctionelements 151 immediately adjacent to or overlying a target surface to begripped. As shown in FIG. 5, for example, the suction elements 151within a boundary 119 (illustrated in dashed line) can be used to grip acorresponding circular surface of a package.

When all of the vacuum regions 117 are active, the end effector 140 canprovide a generally uniform gripping force along the each of thegripping interfaces 121 or entire bottom surface 223. In someembodiments, the bottom surface 223 is a generally continuous andsubstantially uninterrupted surface and the distance or pitch betweensuction elements 151 of adjacent vacuum regions 117 can be less than,equal to, or greater than (e.g., 2×, 3×, 4×, etc.) the pitch betweensuction elements 151 of the same vacuum region 117. The end effector 140can be configured to hold or affix object(s) via attractive forces, suchas achieved by forming and maintaining a vacuum condition between thevacuum regions 117 and the object. For example, the end effector 140 caninclude one or more vacuum regions 117 configured to contact a surfaceof the target object and form/retain the vacuum condition in the spacesbetween the vacuum regions 117 and the surface. The vacuum condition canbe created when the end effector 140 is lowered via the robotic arm 139,thereby pressing the vacuum regions 117 against the surface of thetarget object and pushing out or otherwise removing gases between theopposing surfaces. When the robotic arm 139 lifts the end effector 140,a difference in pressure between the spaces inside the vacuum regions117 and the surrounding environment can keep the target object attachedto the vacuum regions 117. In some embodiments, the air-flow ratethrough the vacuum regions 117 of the end effector 140 can bedynamically adjusted or based on the contact area between the targetobject and a contact or gripping surface of the vacuum regions 117 toensure that a sufficient grip is achieved to securely grip the targetobject. Similarly, the air-flow rate thought the vacuum regions 117 canbe adjusted dynamically to accommodate the weight of the target object,such as increasing the air flow for heavier objects, to ensure thatsufficient grip is achieved to securely grip the target object. Examplesuction elements are discussed in connection with FIG. 15.

FIG. 6 is a functional block diagram of the transfer assembly 104 inaccordance with one or more embodiments of the present technology. Aprocessing unit 150 (PU) can control the movements and/or other actionsof the robotic arm system 132. The PU 150 can receive image data fromsensors (e.g., sensors 161 of the imaging system 160 of FIG. 3), sensors145 of the vision sensor device 143, or other sensors or detectorscapable of collecting image data, including video, still images, lidardata, radar data, or combinations thereof. In some embodiments, theimage data can be indicative or representative of a surface image (SI)of the package 112.

The PU 150 can include any electronic data processing unit whichexecutes software or computer instruction code that could be stored,permanently or temporarily, in memory 152, a digital memory storagedevice or a non-transitory computer-readable media including, but notlimited to, random access memory (RAM), disc drives, magnetic memory,read-only memory (ROM), compact disc (CD), solid-state memory, securedigital cards, and/or compact flash cards. The PU 150 may be driven bythe execution of software or computer instruction code containingalgorithms developed for the specific functions embodied herein. In someembodiments, the PU 150 may be an application-specific integratedcircuit (ASIC) customized for the embodiments disclosed herein. In someembodiments, the PU 150 can include one or more of microprocessors,Digital Signal Processors (DSPs), Programmable Logic Devices (PLDs),Programmable Gate Arrays (PGAs), and signal generators; however, for theembodiments herein, the term “processor” is not limited to such exampleprocessing units and its meaning is not intended to be construednarrowly. For instance, the PU 150 can also include more than oneelectronic data processing unit. In some embodiments, the PU 150 couldbe a processor(s) used by or in conjunction with any other system of therobotic system 100 including, but not limited to, the robotic arm system130, the end effector 140, and/or the imaging system 160. The PU 150 ofFIG. 6 and the processor 202 of FIG. 2 can be the same component ordifferent components.

The PU 150 may be electronically coupled (via, e.g., wires, buses,and/or wireless connections) to systems and/or sources to facilitate thereceipt of input data. In some embodiments, operatively coupled may beconsidered as interchangeable with electronically coupled. It is notnecessary that a direct connection be made; instead, such receipt ofinput data and the providing of output data could be provided through abus, through a wireless network, or as a signal received and/ortransmitted by the PU 150 via a physical or a virtual computer port. ThePU 150 may be programmed or configured to execute the methods discussedherein. In some embodiments, the PU 150 may be programmed or configuredto receive data from various systems and/or units including, but notlimited to, the imaging system 160, end effector 140, etc. In someembodiments, the PU 150 may be programmed or configured to provideoutput data to various systems and/or units.

The imaging system 160 could include one or more sensors 161 configuredto capture image data representative of the packages (e.g., packages 112located on the de-palletizing platform 110 of FIG. 3). In someembodiments, the image data can represent visual designs and/or markingsappearing on one or more surfaces of the from which a determination of aregistration status of the package may be made. In some embodiments, thesensors 161 are cameras configured to work within a targeted (e.g.,visible and/or infrared) electromagnetic spectrum bandwidth and used todetect light/energy within the corresponding spectrum. In some cameraembodiments, the image data is a set of data points forming point cloud,the depth map, or a combination thereof captured from one or morethree-dimensional (3-D) cameras and/or one or more two-dimensional (2-D)cameras. From these cameras, distances or depths between the imagingsystem 160 and one or more exposed (e.g., relative to a line of sightfor the imaging system 160) surfaces of the packages 112 may bedetermined. In some embodiments, the distances or depths can bedetermined by using an image recognition algorithm(s), such ascontextual image classification algorithm(s) and/or edge detectionalgorithm(s). Once determined, the distance/depth values may be used tomanipulate the packages via the robotic arm system. For example, the PU150 and/or the robotic arm system can use the distance/depth values forcalculating the position from where the package may be lifted and/orgripped. It should be noted that data described herein, such as theimage data, can include any analog or digital signal, either discrete orcontinuous, which could contain information or be indicative ofinformation.

The imaging system 160 can include at least one display unit 164configured to present operational information (e.g., status information,settings, etc.), an image of the package(s) 112 captured by the sensors162, or other information/output that may be viewed by one or moreoperators of the robotic system 100 as discussed in detail below. Inaddition, the display units 164 can be configured to present otherinformation such as, but not limited to, symbology representative oftargeted packages, non-targeted packages, registered packages, and/orunregistered instances of the packages.

The vision sensor device 143 can communicate with the PU 150 via wireand/or wireless connections. The vision sensor 145 can be video sensors,CCD sensors, lidar sensors, radar sensors, distance-measuring ordetecting devices, or the like. Output from the vision sensor device 143can be used to generate a representation of the package(s), such as adigital image and/or a point cloud, used for implementingmachine/computer vision (e.g., for automatic inspection, robot guidance,or other robotic applications). The field of view (e.g., 30 degrees, 90degrees, 120 degrees, 150 degrees, 180 degrees, 210 degrees, 270 degreesof horizontal and/or vertical FOV) and the range capability of thevision sensor device 143 can be selected based on the configuration thegripper assembly 141. (FIG. 4 shows an exemplary horizontal FOV of about90 degrees.) In some embodiments, the vision sensors 145 are lidarsensors with one or more light sources (e.g., lasers, infrared lasers,etc.) and optical detectors. The optical detectors can detect lightemitted by the light sources and reflected by surfaces of packages. Thepresence and/or distance to packages can be determined based on thedetected light. In some embodiments, the sensors 145 can scan an area,such as substantially all of a vacuum gripping zone (e.g., vacuumgripping zone 125 of FIG. 4). For example, the sensors 154 can includeone or more deflectors that move to deflect emitted light across adetection zone. In some embodiments, the sensors 154 are scanninglaser-based lidar sensors capable of scanning vertically and/orhorizontally, such as a 10° lidar scan, a 30° lidar scan, a 50° lidarscan, etc.). The configuration, FOV, sensitivity, and output of thesensors 145 can be selected based on the desired detection capabilities.In some embodiments, the sensors 145 can include both presence/distancedetectors (e.g., radar sensors, lidar sensor, etc.) and one or morecameras, such as three-dimensional or two-dimensional cameras. Distancesor depths between the sensors and one or more surfaces of packages canbe determined using, for example, one or more image recognitionalgorithms. The display unit 147 can be used to view image data, viewsensor status, perform calibration routines, view logs and/or reports,or other information or data, such as, but not limited to, symbologyrepresentative of targeted, non-targeted, registered, and/orunregistered instances of packages 112.

To control the robotic system 100, the PU 150 can use output from one orboth the sensors 145 and sensors 161. In some embodiments, image outputfrom sensors 161 is used to determine an overall transfer plan,including an order for transporting objects. Image output from thesensors 145, as well as sensors 205 (e.g., a force detector assembly),can be used to position a multi-gripping assembly with respect toobjects, confirm object pickup, and monitor transport steps.

With continued reference to FIG. 6, the RDS 170 could include anydatabase and/or memory storage device (e.g., a non-transitorycomputer-readable media) configured to store the registration records172 for a plurality of the packages 112, data 173 for vacuum grippers.For example, the RDS 170 can include read-only memory (ROM), compactdisc (CD), solid-state memory, secure digital cards, compact flashcards, and/or data storage servers or remote storage devices.

In some embodiments, the registration records 172 can each includephysical characteristics or attributes for the corresponding package112. For example, each registration record 172 can include, but is notbe limited to, one or more template SIs, vision data (e.g., referenceradar data, reference lidar data, etc.), 2-D or 3-D size measurements, aweight, and/or center of mass (CoM) information. The template SIs canrepresent known or previously determined visible characteristics of thepackage including the design, marking, appearance, exteriorshape/outline, or a combination thereof of the package. The 2-D or 3-Dsize measurements can include lengths, widths, heights, or combinationthereof for the known/expected packages.

In some embodiments, the RDS 170 can be configured to receive a newinstance of the registration record 172 (e.g., for a previously unknownpackage and/or a previously unknown aspect of a package) created inaccordance with the embodiments disclosed below. Accordingly, therobotic system 100 can automate the process for registering the packages112 by expanding the number of registration records 172 stored in theRDS 170, thereby making a de-palletizing operation more efficient withfewer unregistered instances of the packages 112. By dynamically (e.g.,during operation/deployment) updating the registration records 172 inthe RDS 170 using live/operational data, the robotic system 100 canefficiently implement a computer-learning process that can account forpreviously unknown or unexpected conditions (e.g., lighting conditions,unknown orientations, and/or stacking inconsistencies) and/or newlyencountered packages. Accordingly, the robotic system 100 can reduce thefailures resulting from “unknown” conditions/packages, associated humanoperator interventions, and/or associated task failures (e.g., lostpackages and/or collisions).

The RDS 170 can include vacuum gripper data 173, including, but notlimited to, characteristics or attributes, including the number ofaddressable vacuum regions, carrying capability of a vacuum gripperdevice (e.g., multi-gripper assembly), vacuum protocols (e.g., vacuumlevels, airflow rates, etc.), or other data used to control the roboticarm system 130 and/or end effector 140. An operator can inputinformation about the vacuum gripper installed in the robotic arm system130. The RDS 170 then identifies vacuum gripper data 173 correspondingto the vacuum gripper device for operation. In some embodiments, thevacuum gripper device (e.g., gripper assembly 141 of FIG. 3) isautomatically detected by the robotic arm 139, and the RDS 170 is usedto identify information about the detected vacuum gripper device. Theidentified information can be used to determine settings of the vacuumgripper device. Accordingly, different vacuum gripper devices ormulti-gripper assemblies to be installed and used with the robotic armsystem 130.

End Effectors

FIG. 7 is a front, top isometric view of a portion of the end effector140 in accordance with one or more embodiments of the presenttechnology. FIG. 8 is a front, bottom isometric view of the end effector140 of FIG. 7. Referring now to FIG. 7, the end effector 140 can includea mounting interface or bracket 209 (“mounting bracket 209”) and a forcedetector assembly 205 coupled to the bracket 209 and the gripperassembly 141. A fluid line 207 can be fluidically coupled to apressurization device, such as a vacuum source 221 (not shown in FIG. 8)and the gripper assembly 141.

The FOV (a variable or a fixed FOV) of the vision sensor device 143 isdirected generally underneath the gripper assembly 141 to providedetection of any objects carried underneath the gripper assembly 141.The vision sensor device 143 can be positioned along the perimeter ofthe end effector 140 such that the vision sensor device 143 is below thesubstantially horizontal plane of one or more of the vacuum regions 117(one identified), and more specifically, the gripping surface of thegripping interface 121 (one identified). The term “substantiallyhorizontal” generally refers to an angle within about +/−2 degrees ofhorizontal, for example, within about +/−1 degree of horizontal, such aswithin about +/−0.7 degrees of horizontal. In general, the end effector140 includes multiple vacuum regions 117 that enable the robotic system100 to grip the target objects that otherwise would not be grippable bya single instance of the vacuum regions 117. However, a larger area willbe obscured from detection sensors due to the larger size of the endeffector 140 relative to the end effector 140 with the single instanceof vacuum regions 117. As one advantage, the vision sensor device 143positioned below the horizontal plane of the gripping interface 121 canprovide the vision sensor device 143 with a FOV that includes thegripping interface 121 during contact initiation with objects, includingthe target object, that would normally be obscured for other instancesof the vision sensor device 143 that are not attached to the endeffector 140 or positioned in different locations within the operatingenvironment of the robotic system 100. As such, the unobscured FOV canprovide the robotic system with real-time imaging sensor informationduring the gripping operations, which can enable real-time or on the flyadjustments to the position and motion of the end effector 140. As afurther advantage, the proximity between the vision sensor device 143positioned below the horizontal plane of the gripping interface 121 andobjects (e.g., non-targeted objects 112 a, 112 b of FIG. 3) increasesthe precision and accuracy during the gripping operation, which canprotect or prevent damage to the target object 112 and the non-targetedobjects adjacent to the target object 112,a 112 b from the end-effector140, such as by crushing of the objects.

For illustrative purposes, the vision sensor device 143 can bepositioned at a corner of the end-effector 140 along the effector width,however, it is understood that the vision sensor device 143 can bepositioned differently. For example, the vision sensor device 143 can bepositioned at the center of the width or length of the end-effector 140.As another example, the vision sensor device 143 can be positioned atanother corner or other positions along the effector length.

The vacuum source 221 (FIG. 7) can include, without limitation, one ormore pressurization devices, pumps, valves, or other types of devicescapable of providing a negative pressure, drawing a vacuum (includingpartial vacuum), or creating a pressure differential. In someembodiments, air pressure can either be controlled with one or moreregulators, such as a regular between the vacuum source 221 and thegripper assembly 141 or a regulator in the gripper assembly 141. Whenthe vacuum source 221 draws a vacuum, air can be drawn (indicated byarrows in FIG. 8) into the bottom 224 of the gripper assembly 141. Thepressure level can be selected based on the size and weight of theobjects to be carried. If the vacuum level is too low, the gripperassembly 141 may not be able to pick up the target object(s). If thevacuum level is too high, the outside of the package could be damaged(e.g., a package with an outer plastic bag could be torn due to a highvacuum level). According to some embodiments, the vacuum source 221 canprovide vacuum levels of approximately 100 mBar, 500 mBar, 1,000 mBar,2,000 mBar, 4,000 mBar, 6,000 mBar, 8,000 mBar, or the like. Inalternative embodiments, higher or lower vacuum levels are provided. Insome embodiments, the vacuum level can be selected based on the desiredgripping force. The vacuum gripping force of each region 117 can beequal to or greater than about 50N, 100N, 150N, 200N, or 300N at avacuum level (e.g., 25%, 50%, or 75% maximum vacuum level, i.e., maximumvacuum level for the vacuum source 221). These gripping forces can beachieved when picking up a cardboard box, plastic bag, or other suitablepackage for transport. Different vacuum levels can be used, includingwhen transporting the same object or different objects. For example, arelatively high vacuum can be provided to initially grip the object.Once the package has been gripped, the gripping force (and therefore thevacuum level) required to continue to hold the object can be reduced, soa lower vacuum level can be provided. The gripping vacuum can beincreased to maintain a secure grip when performing certain tasks.

The force detector assembly 205 can include one or more sensors 203 (oneillustrated) configured to detect forces indicative of the load carriedby the end effector 140. The detected measurements can include linearforces measurements along an axis and/or axes of a coordinate system,moment measurements, pressures measurements, or combinations thereof. Insome embodiments, the sensor 203 can be a F-T sensor that includes acomponent with six-axis force sensors configured to detect up to threeaxis forces (e.g., forces detected along x-, y-, and z-axes of aCartesian coordinate system) and/or three axis moments (e.g., momentsdetected about x-, y-, and z-axes of the Cartesian coordinate system).In some embodiments, the sensor 203 could include a built-in amplifierand microcomputer for signal processing, an ability to make static anddynamic measurements, and/or an ability to detect instant changes basedon a sampling interval. In some embodiments with reference made to theCartesian coordinate system, force measurement(s) along one or more axis(i.e., F(x-axis), F(y-axis), and/or F(z-axis)) and/or momentmeasurement(s) about one or more axis (i.e., M(x-axis), M(y-axis),and/or M(z-axis)) may be captured via the sensor 203. By applying CoMcalculation algorithms, the weight of the packages, positions ofpackages, and/or number of packages can be determined. For example, theweight of the packages may be computed as a function of the forcemeasurement(s), and the CoM of the package may be computed as a functionof the force measurement(s) and the moment measurement(s). In someembodiments, the weight of the packages is computed as a function of theforce measurement(s), package position information from the visionsensor device 143, and/or gripping information (e.g., locations at whicha seal with the package(s) is achieved). In some embodiments, thesensors 203 could be communicatively coupled with a processing unit(e.g., PU 150 of FIG. 6) via wired and/or wireless communications.

In some embodiments, output readings from both the force detectorassembly 205 and the vision sensor device 143 can be used. For example,relative positions of objects can be determined based on output from thevision sensor device 143. The output from the force detector assembly205 can then be used to determine information about each object, such asthe weight/mass of each object. The force detector assembly 205 caninclude contact sensors, pressure sensors, force sensors, strain gauges,piezoresistive/piezoelectric sensors, capacitive sensors,elastoresistive sensors, torque sensors, linear force sensors, or othertactile sensors, configured to measure a characteristic associated witha direct contact between multiple physical structures or surfaces. Forexample, the force detector assembly 205 can measure the characteristicthat corresponds to a grip of the end-effector on the target object ormeasure the weight of the target object. Accordingly, the force detectorassembly 205 can output a contact measure that represents a quantifiedmeasure, such as a measured force or torque, corresponding to a degreeof contact or attachment between the gripper and the target object. Forexample, the contact measure can include one or more force or torquereadings associated with forces applied to the target object by theend-effector. The output from the force detector assembly 205 or otherdetectors that are integrated with or attached to the end effector 140.For example, the sensor information from the contact sensors, such asweight or weight distribution of the target object based on the forcetorque sensor information, in combination with the imaging sensorinformation, such as dimension of the target object, can be used by therobotic system to determine the identity of the target object, such asby an auto-registration or automated object registration system.

FIG. 9 is an exploded isometric view of the gripper assembly 141 inaccordance with one or more embodiments of the present technology. Thegripper assembly 141 includes a housing 260 and an internal assembly263. The housing 260 can surround and protect the internal componentsand can define an opening 270 configured to receive at least a portionof the force detector assembly 205. The internal assembly 263 caninclude a gripper bracket assembly 261 (“bracket assembly 261”), amanifold assembly 262, and a plurality of grippers 264 a, 264 b, 264 c(collectively “grippers 264”). The bracket assembly 261 can hold each ofthe vacuum grippers 264, which can be fluidically coupled in series orparallel to a fluid line (e.g., fluid line 207 of FIG. 7) via themanifold assembly 262, as discussed in connection with FIGS. 10 and 11.In some embodiments, the bracket assembly 261 includes an elongatedsupport 269 and brackets 267 (one identified) connecting the grippers264 to the elongated support 269. The gripper assembly 141 can includesuction elements, sealing members (e.g., sealing panels), and othercomponents discussed in connection with FIGS. 13-15.

FIGS. 10 and 11 are a rear, top isometric view and a plan view,respectively, of components of the gripper assembly in accordance withone or more embodiments of the present technology. The manifold assembly262 can include gripper manifolds 274 a, 274 b, 274 c (collectively“manifolds 274”) coupled to respective grippers 264 a, 264 b, 264 c. Forexample, the manifold 274 a controls air flow associated with thegripper 264 a. In some embodiments, the manifolds 274 can be connectedin parallel or series to a pressurization source, such as the vacuumsource 221 of FIG. 7. In other embodiments, each manifold 274 can befluidly coupled to an individual pressurization device.

The manifolds 274 can be operated to distribute the vacuum to one, some,or all of the grippers 264. For example, the manifold 274 a can be in anopen state to allow air to flow through the bottom of the gripper 264 a.The air flows through the manifold 274 a, and exits the vacuum gripperassembly via a line, such as the line 207 of FIG. 7. The other manifolds274 b, 274 c can be in a closed state to prevent suction at themanifolds 274 b, 274 c. Each manifold 274 a can include, withoutlimitation, one or more lines connected to each of the suction elements.In other embodiments, the suction elements of the gripper 264 a areconnected to an internal vacuum chamber. The gripper manifolds 274 caninclude, without limitation, one or more lines or passages, valves(e.g., check valves, globe valves, three-way valves, etc.), pneumaticcylinders, regulators, orifices, sensors, and/or other componentscapable of controlling the flow of fluid. Each manifold 274 can be usedto distribute suction evenly or unevenly to suction elements or groupsof suction elements to produce uniform or nonuniform vacuum grippingforces. An electronics line can communicatively couple the manifolds 274to a controller to provide power to and control over components of themodules and components thereof. In one embodiment, individual manifolds274 can include common interfaces and plugs for use with commoninterfaces and plugs, which may make it possible to add and removemanifolds 274 and components quickly and easily, thereby facilitatingsystem reconfiguration, maintenance, and/or repair.

The number, arrangement, and configuration of the grippers can beselected based on a desired number of addressable vacuum regions. FIG.12 is an isometric view of internal components of a vacuum gripperassembly 300 (housing not shown) suitable for use with the environmentof FIGS. 1-2 and the transfer assembly 141 of FIGS. 3-6 in accordancewith one or more embodiments of the present technology. The vacuumgripper assembly 300 can include six vacuum grippers 302 (oneidentified) in a generally rectangular arrangement. In otherembodiments, the grippers can be in a circular arrangement, squarearrangement, or other suitable arrangement and can have similar ordifferent configurations. The grippers can have other shapes including,without limitation, oval shapes, non-polygonal shapes, or the like. Thegrippers can include suction elements (e.g., suction tubes, suctioncups, sealing member, etc.), sealing member, valve plates, grippermechanisms, and other fluidic components for providing grippingcapability.

One or more sensors, vision sensor devices, and other componentdiscussed in connection with FIGS. 1-11 can be incorporated into or usedwith the vacuum gripper assembly 300. Suction elements, sealing member,and other components are discussed in connection with FIGS. 13-15.

The vacuum grippers can be arranged in series. For example, vacuumgrippers can be arranged one next to another in a I×3 configuration,which provides two lateral gripping position and one central grippingposition. However, it is understood that the end effectors can include adifferent number of the vacuum grippers, suction channel banks, orvacuum regions in different configurations relative to one another. Forexample, the end effector can include four of the vacuum grippers orsuction channel banks arranged in a 2×2 configuration. The vacuumregions can have a width dimension that is the same or similar to thelength dimension to have a symmetric square shape. As another example,the end effector can include a different number of the vacuum regions,such as two of vacuum regions or more than three of vacuum regionshaving the same or different length dimension and/or width dimensionform one another. In yet a further example, the vacuum grippers can bearranged in various configurations, such as a 2×2 configuration withfour of the vacuum regions, a 1:2:2 configuration that includes five ofthe vacuum grippers, or other geometric arrangements and/orconfigurations.

FIG. 13 shows a multi-gripper assembly 400 (“gripper assembly 400”)suitable for use with robotic systems (e.g., robotic system 100 of FIGS.1-2) in accordance with some embodiments of the present technology. FIG.14 is an exploded view of the gripper assembly 400 of FIG. 13. Thegripper assembly 400 can be any gripper or gripper assembly configuredto grip a package from a stationary position (e.g., a stationaryposition on a de-palletizing platform such as a platform 110 of FIG. 3).The gripper assembly device 400 can include a gripper mechanism 410 anda contact or sealing member 412 (“sealing member 412”). The grippermechanism 410 includes a main body 414 and a plurality of suctionelements 416 (one identified in FIG. 14) each configured to pass throughan opening 418 (one identified in FIG. 14) of the member 412. Whenassembled, each of the suction elements 416 can extend through, eitherpartially or completely, a corresponding opening 418. For example, thesuction elements 416 can extend through a first side 419 toward thesecond side 421 of the sealing member 412.

FIG. 15 is a partial cross-sectional view of the sealing member 412 andthe suction element 416. The suction element 416 can be in fluidcommunication with a line (e.g., line 422 of FIG. 14) via a vacuumchamber and/or internal conduit 430. A valve 437 (e.g., check valve,relief valve, etc.) can be positioned along an air flow path 436. Asensor 434 can be positioned to detect a vacuum level and can be incommunication, via a wired or wireless connection, with a controller(e.g., controller 109 of FIG. 1) or processing unit (e.g., processingunit 150 of FIG. 6). A lower end 440 of the suction element 416 caninclude, without limitation, a suction cup or another suitable featurefor forming a desired seal (e.g., a generally airtight seal or othersuitable seal) with an object's surface. When the lower end 440 isproximate to or contacts the object, the object can be pulled againstthe sealing member 412 when air is drawn into a port/inlet 432 (“inlet432”) of the suction element 416 (as indicated by arrows). The air flowsupwardly along a flow path 426 and through a passageway 433 of thesuction element 416. The air can flow through a valve 437 and into theconduit 430. In some embodiments, the conduit 430 can be connected to avacuum chamber 439. For example, some or all of the suction elements 416can be connected to the vacuum chamber 439. In other embodiments,different groups of suction elements 416 can be in fluid communicationwith different vacuum chambers. The suction elements 416 can have anundulating or bellowed configuration, as shown, to allow axialcompression without constricting the airflow passageway 433 therein. Theconfigurations, heights, and dimensions of the suction elements 416 canbe selected based on the desired amount of compressibility.

The sealing member 412 can be made, in whole or part, of compressiblematerials configured to deform to accommodate surfaces with differentgeometries, including highly contoured surfaces. The sealing member 412can be made, in whole or in part, of foam, including closed-cell foam(e.g., foam rubber). The material of the sealing member 412 can beporous to allow small amounts of air flow (i.e., air leakage) to avoidapplying high negative pressures that could, for example, damagepackaging, such as plastic bags.

Operational Flow

FIG. 16 is a flow diagram of a method 490 for operating a robotic systemin accordance with one or more embodiments of the present disclosure. Ingeneral, a transport robot can receive image data representative of atleast a portion of a pickup environment. The robot system can identifytarget objects based on the received image data. The robot system canuse a vacuum gripper assembly to hold onto the identified targetobject(s). Different units, assemblies, and subassemblies of the robotsystems 100 of FIG. 1 can perform the method 490. Details of the method490 are discussed in detail below.

At block 500, the robotic system 100 can receive image datarepresentative of at least a portion of an environment. For example, thereceived image data can be representative of at least a portion of thestack 165 at the pickup environment 163 of FIG. 3. The image data caninclude, without limitation, video, still images, lidar data, radardata, bar code data, or combinations thereof. In some embodiments, forexample, the sensors 161 of FIG. 3 can capture video or still imagesthat are transmitted (e.g., via a wired or wireless connection) to acomputer or controller, such as the controller 109 of FIGS. 1 and 6.

At block 502, the computer 109 (FIG. 1) can analyze image data toidentify target objects in a group of objects, a stacked of objects,etc. For example, the controller 109 can identify individual objectsbased on the received image data and surface images/data stored by theRDS 170 (FIG. 6). In some embodiments, information from the drop offlocation is used to select the target object. For example, a targetobject can be selected based on the amount of available space at thedrop off location, preferred stacking arrangement, etc. A user can inputselection criteria for determining the order of object pick up. In someembodiments, a mapping of the pickup environment (e.g., pickupenvironment 163 of FIG. 3) can be generated based on the received imagedata. In some mapping protocols, edge detection algorithms are used toidentify edges of objects, surfaces, etc. The mapping can be analyzed todetermine which objects at the pickup region are capable of beingtransported together. In some embodiments, a group of objects capable ofbeing simultaneously lifted and carried by the vacuum gripper areidentified as targeted objects.

The robotic system 100 of FIG. 1 can select the target package or object112 from source objects as the target of a task to be performed. Forexample, the robotic system 100 can select the target object to bepicked up according to a predetermined sequence, set of rules, templatesof object outlines, or a combination thereof. As a specific example, therobotic system 100 can select the target package as an instance of thesource packages that are accessible to the end effector 140, such as aninstances of the source packages 112 located on top of a stack of thesource packages, according to the point cloud/depth map representing thedistances and positions relative to a known location of the imagedevices. In another specific example, the robotic system 100 can selectthe target object as an instance of the source packages 112 located at acorner or edge and have two or more surfaces that are exposed to oraccessible to the end effector 140. In a further specific example, therobotic system 100 can select the target object according to apredetermined pattern, such as left to right or nearest to furthestrelative to a reference location, without or minimally disturbing ordisplacing other instances of the source packages.

At block 504, the controller 109 can select the vacuum grippers orregions for gripping the target objects. For example, the controller 109(FIG. 1) can select the vacuum region 117 a (FIG. 4) for gripping thepackage 112, illustrated in FIG. 3, because substantially the entirepackage 112 (i.e., target object) is directly beneath the vacuum region117 a. A vacuum to be drawn through substantially all of the suctionelements 151 (e.g., at least 90%, 95%, 98% of the suction elements 151)of the vacuum region 117 a of FIG. 4.

At block 506, the controller 109 generates one or more commands forcontrolling the robotic system 100. In some modes of operation, thecommands can cause the robotic system to suck in air at the identifiedor selected addressable vacuum regions. For example, the controller 109can generate one or more pickup commands to cause a vacuum source (e.g.,vacuum source 221 of FIG. 7) to provide a vacuum at a selected vacuumlevel. The vacuum level can be selected based on the weight or mass ofthe target object(s), tasks to be performed, etc. Commands can be sentto the gripper assembly 141 to cause the manifold 262 to operate toprovide suction at the selected regions or grippers. Feedback from thevision sensor device 143 (FIG. 7) can be used to monitor the pickup andtransfer process.

At block 508, the vision sensor device 143 can be used to verify theposition of the end effector 140 relative to objects, including sourceor target objects, such as the packages 112 of FIG. 1. The vision sensordevice 143 can be used to continuously or periodically monitor therelative position of the end effector 140 relative to objects before andduring object pickup, during object transport, and/or during and afterobject drop off. The output from vision sensor device 143 can also beused to count objects, (e.g., count the number of target or sourceobjects) or otherwise analyze objects, including analyzing stacks ofobjects. The vision sensor device 143 can also be used to obtainenvironmental information used to navigate the robotic system 100.

At block 510, the controller 109 generates command to cause actuationdevices (e.g., actuation devices 212), motors, servos, actuators, andother components of the robotic arm 139 to move the gripper assembly141. Transfer commands can be generated by the robotic system to causethe robotic transport arm to robotically move the gripper assembly 141carrying the objects between locations. The transport commands can begenerated based on a transport plan that includes a transport path todeliver the object to a drop off location without causing the object tostrike another object. The vision sensor device 143 (FIG. 7) can be usedto avoid collisions.

The method 490 can be performed to grip multiple target objects. The endeffector 140 can be configured to grip multiple instances of the targetpackage or object from among the source packages or objects. Forexample, the robotic system 100 can generate instructions for the endeffector 140 to engage multiple instances of the vacuum regions 117 toperform the gripping operation to simultaneously grip multiple instancesof the target object. As a specific example, the end effector 140 can beused to execute instructions for the gripping operation of grippingmultiple instances of the target object separately and in sequence, oneafter the other. For instance, the instructions can include performingthe gripping operation using one of the suction channel banks 117 togrip a first instance of the target object 112 that is in one pose orone orientation, then, if necessary, repositioning the end effector 140to engage a second or different instance of the vacuum regions 117 togrip a second instance of the target object. In another specificexample, the end effector 140 can be used to execute instructions forthe gripping operation of simultaneous gripping of separate instances ofthe target object. For instance, the end effector 140 can be positionedto simultaneously contact two or more instances of the target object andengage each of the corresponding instances of vacuum regions 117 toperform the gripping operation on each of the multiple instances of thetarget object. In the above embodiments, each of the suction channelbanks 117 can be independently operated as necessary to perform thedifferent gripping operations.

FIG. 17 is a flow diagram of a method 700 for operating the roboticsystem 100 of FIG. 1 according to a base plan in accordance with one ormore embodiments of the present technology. The method 700 includessteps that can be incorporated into the method 490 of FIG. 16 and can beimplemented based on executing the instructions stored on one or more ofthe storage devices 204 of FIG. 2 with one or more of the processors 202of FIG. 2 or the controller 109 of FIG. 6. Data captured by the visionsensor devices and sensor output can be used at various steps of themethod 700 as detailed below.

At block 702, the robotic system 100 can interrogate (e.g., scan) one ormore designated areas, such as the pickup area and/or the drop area(e.g., a source drop area, a destination drop area, and/or a transitdrop area). In some embodiments, the robotic system 100 can use (via,e.g., commands/prompts sent by the processors 202 of FIG. 2) one or moreof the imaging devices 222 of FIG. 2, sensors 161 and/or 145 of FIG. 6,or other sensors to generate imaging results of the one or moredesignated areas. The imaging results can include, without limitation,captured digital images and/or point clouds, object position data, orthe like.

At block 704, the robotic system 100 can identify the target package 112of FIG. 1 and associated locations (e.g., the start location 114 of FIG.1 and/or the task location 116 of FIG. 1). In some embodiments, forexample, the robotic system 100 (via, e.g., the processors 202) cananalyze the imaging results according to a pattern recognition mechanismand/or a set of rules to identify object outlines (e.g., perimeter edgesor surfaces). The robotic system 100 can further identify groupings ofobject outlines (e.g., according to predetermined rules and/or posetemplates) as corresponding to each unique instance of objects. Forexample, the robotic system 100 can identify the groupings of the objectoutlines that correspond to a pattern (e.g., same values or varying at aknown rate/pattern) in color, brightness, depth/location, or acombination thereof across the object lines. Also, for example, therobotic system 100 can identify the groupings of the object outlinesaccording to predetermined shape/pose templates defined in the masterdata.

From the recognized objects in the pickup location, the robotic system100 can select (e.g., according to a predetermined sequence or set ofrules and/or templates of object outlines) one as the target packages112. For example, the robotic system 100 can select the targetpackage(s) 112 as the object(s) located on top, such as according to thepoint cloud representing the distances/positions relative to a knownlocation of the sensor. Also, for example, the robotic system 100 canselect the target package 112 as the object(s) located at a corner/edgeand have two or more surfaces that are exposed/shown in the imagingresults. The available vacuum grippers and/or regions can also be usedto select the target packages. Further, the robotic system 100 canselect the target package 112 according to a predetermined pattern(e.g., left to right, nearest to furthest, etc. relative to a referencelocation).

In some embodiments, the end effector 140 can be configured to gripmultiple instances of the target packages 112 from among the sourcepackage. For example, the robotic system 100 can generate instructionsfor the end effector 140 to engage multiple instances of the gripperregions 117 to perform the gripping operation to simultaneously gripmultiple instances of the target packages 112. As a specific example,the end effector 140 can be used to execute instructions for thegripping operation of gripping multiple instances of the target package112 separately and in sequence, one after the other. For instance, theinstructions can include performing the gripping operation using one ofthe gripper regions 117 to grip a first instance of the target package112 that is in one pose or one orientation, then, if necessary,repositioning the end effector 140 to engage a second or differentinstance of the gripper regions 117 to grip a second instance of thetarget package 112. In another specific example, the end effector 140can be used to execute instructions for the gripping operation ofsimultaneous gripping of separate instances of the target package 112.For instance, the end effector 140 can be positioned to simultaneouslycontact two or more instances of the target package 112 and engage eachof the corresponding instances of gripper regions 117 to perform thegripping operation on each of the multiple instances of the targetpackage 112. In the above embodiments, each of the gripper regions 117can be independently operated as necessary to perform the differentgripping operations.

For the selected target package 112, the robotic system 100 can furtherprocess the imaging result to determine the start location 114 and/or aninitial pose. For example, the robotic system 100 can determine theinitial pose of the target package 112 based on selecting from multiplepredetermined pose templates (e.g., different potential arrangements ofthe object outlines according to corresponding orientations of theobject) the one that corresponds to a lowest difference measure whencompared to the grouping of the object outlines. Also, the roboticsystem 100 can determine the start location 114 by translating alocation (e.g., a predetermined reference point for the determined pose)of the target package 112 in the imaging result to a location in thegrid used by the robotic system 100. The robotic system 100 cantranslate the locations according to a predetermined calibration map.

In some embodiments, the robotic system 100 can process the imagingresults of the drop areas to determine open spaces between objects. Therobotic system 100 can determine the open spaces based on mapping theobject lines according to a predetermined calibration map thattranslates image locations to real-world locations and/or coordinatesused by the system. The robotic system 100 can determine the open spacesas the space between the object lines (and thereby object surfaces)belonging to different groupings/objects. In some embodiments, therobotic system 100 can determine the open spaces suitable for the targetpackage 112 based on measuring one or more dimensions of the open spacesand comparing the measured dimensions to one or more dimensions of thetarget package 112 (e.g., as stored in the master data). The roboticsystem 100 can select one of the suitable/open spaces as the tasklocation 116 according to a predetermined pattern (e.g., left to right,nearest to furthest, bottom to top, etc. relative to a referencelocation).

In some embodiments, the robotic system 100 can determine the tasklocation 116 without or in addition to processing the imaging results.For example, the robotic system 100 can place the objects at theplacement area according to a predetermined sequence of actions andlocations without imaging the area. Additionally, the sensors (e.g.,vision sensor device 143) attached to the vacuum gripper assembly 141can output image data used to periodically image the area. The imagingresults can be updated based on the additional image data. Also, forexample, the robotic system 100 can process the imaging result forperforming multiple tasks (e.g., transferring multiple objects, such asfor objects located on a common layer/tier of a stack).

At block 706, the robotic system 100 can calculate a base plan for thetarget package 112. For example, the robotic system 100 can calculatethe base motion plan based on calculating a sequence of commands orsettings, or a combination thereof, for the actuation devices 212 ofFIG. 2 that will operate the robotic system 132 of FIG. 3 and/or theend-effector (e.g., the end-effector 140 of FIGS. 3-5). For some tasks,the robotic system 100 can calculate the sequence and the setting valuesthat will manipulate the robotic system 132 and/or the end-effector 140to transfer the target package 112 from the start location 114 to thetask location 116. The robotic system 100 can implement a motionplanning mechanism (e.g., a process, a function, an equation, analgorithm, a computer-generated/readable model, or a combinationthereof) configured to calculate a path in space according to one ormore constraints, goals, and/or rules. For example, the robotic system100 can use predetermined algorithms and/or other grid-based searches tocalculate the path through space for moving the target package 112 fromthe start location 114 to the task location 116. The motion planningmechanism can use a further process, function, or equation, and/or atranslation table, to convert the path into the sequence of commands orsettings, or combination thereof, for the actuation devices 212. Inusing the motion planning mechanism, the robotic system 100 cancalculate the sequence that will operate the robotic arm 206 (FIG. 3)and/or the end-effector 140 (FIG. 3) and cause the target package 112 tofollow the calculated path. The vision sensor device 143 can be used toidentify any obstructions and recalculate the path and refine the baseplan.

At block 708, the robotic system 100 can begin executing the base plan.The robotic system 100 can begin executing the base motion plan based onoperating the actuation devices 212 according to the sequence ofcommands or settings or combination thereof. The robotic system 100 canexecute a first set of actions in the base motion plan. For example, therobotic system 100 can operate the actuation devices 212 to place theend-effector 140 at a calculated location and/or orientation about thestart location 114 for gripping the target package 112 as illustrated inblock 752.

At block 754, the robotic system 100 can analyze the position of objectsusing sensor information (e.g., information from the vision sensordevice 143, sensors 216, force detector assembly 205) obtained beforeand/or during the gripping operation, such as the weight of the targetpackage 112, the center of mass of the target package 112, the relativeposition of the target package 112 with respect to vacuum regions, or acombination thereof. The robotic system 100 can operate the actuationdevices 212 and vacuum source 221 (FIG. 7) to have the end-effector 140engage and grip the target package 112. The image data from the visionsensor device 143 and/or data from the force sensor assembly 205 can beused to analyze the position and number of the target packages 112. Atblock 755, the vision sensor device 143 can be used to verify theposition of the end effector 140 relative to target packages 112 orother objects. In some embodiments, as illustrated at block 756, therobotic system 100 can perform an initial lift by moving theend-effector up by a predetermined distance. In some embodiments, therobotic system 100 can reset or initialize an iteration counter ‘i’ usedto track a number of gripping actions.

At block 710, the robotic system 100 can measure the established grip.The robotic system 100 can measure the established grip based onreadings from the force detector assembly 205 of FIG. 7, vision sensordevice 143, or other sensors, such as the pressure sensors 434 (FIG.15). For example, the robotic system 100 can determine the gripcharacteristics by using one or more of force detector assembly 205 ofFIG. 3 to measure a force, a torque, a pressure, or a combinationthereof at one or more locations on the robotic arm 139, one or morelocations on the end-effector 140, or a combination thereof. In someembodiments, such as for the grip established by the assembly 141,contact or force measurements can correspond to a quantity, a location,or a combination thereof of the suction elements (e.g., suction elements416 of FIG. 14) contacting a surface of the target package 112 andholding a vacuum condition therein. Additionally or alternative, thegrip characteristic can be determined based on output from the visionsensor device 143. For example, image data from the sensor detector 143can be used to determine whether the object moves relative to the endeffector 140 during transport.

At decision block 712, the robotic system 100 can compare the measuredgrip to a threshold (e.g., an initial grip threshold). For example, therobotic system 100 can compare the contact or force measurement to apredetermined threshold. The robot system 100 can also compare imagedata from the detector 143 to reference image data (e.g., image datacaptured at initial object pickup) to determine whether the grippedobjects have moved, for example, relative to one another or relative tothe gripper assembly 141. Accordingly, the robotic system 100 candetermine whether the contact/grip is sufficient to continuemanipulating (e.g., lifting, transferring, and/or reorienting) thetarget package(s) 112.

When the measured grip fails to satisfy the threshold, the roboticsystem 100 can evaluate whether the iteration count for regripping thetarget packages(s) 112 has reached an iteration threshold, asillustrated at decision block 714. While the iteration count is lessthan the iteration threshold, the robotic system 100 can deviate fromthe base motion plan when the contact or force measurement fails tosatisfy (e.g., is below) the threshold. Accordingly, at block 720, therobotic system 100 can operate the robotic arm 139 and/or theend-effector 140 to execute a regripping action not included in the basemotion plan. For example, the regripping action can include apredetermined sequence of commands or settings, or a combinationthereof, for the actuation devices 212 that will cause the robotic arm139 to lower the end-effector 140 (e.g., in reversing the initial lift)and/or cause the end-effector 140 to release the target package(s) 112and regrip the target package(s) 112. In some embodiments, thepredetermined sequence can further operate the robotic arm 139 to adjusta position of the gripper after releasing the target object and beforeregripping it or altering the areas at which the vacuum is drawn. Inperforming the regripping action, the robotic system 100 can pauseexecution of the base motion plan. After executing the regrippingaction, the robotic system 100 can increment the iteration count.

After regripping the object, the robotic system 100 can measure theestablished grip as described above for block 710 and evaluate theestablished grip as described above for block 712. The robotic system100 can attempt to regrip the target package 112 as described aboveuntil the iteration count reaches the iteration threshold. When theiteration count reaches the iteration threshold, the robotic system 100can stop executing the base motion plan, as illustrated at block 716. Insome embodiments, the robotic system 100 can solicit operator input, asillustrated at block 718. For example, the robotic system 100 cangenerate an operator notifier (e.g., a predetermined message) via thecommunication devices 206 of FIG. 2 and/or the input-output devices 208of FIG. 2. In some embodiments, the robotic system 100 can cancel ordelete the base motion plan, record a predetermined status (e.g., anerror code) for the corresponding task, or perform a combinationthereof. In some embodiments, the robotic system 100 can reinitiate theprocess by imaging the pickup/task areas (block 702) and/or identifyinganother item in the pickup area as the target object (block 704) asdescribed above.

When the measured grip (e.g., measured grips for each retained package)satisfies the threshold, the robotic system 100 can continue executingremaining portions/actions of the base motion plan, as illustrated atblock 722. Similarly, when the contact measure satisfies the thresholdafter regripping the target package 112, the robotic system 100 canresume execution of the paused base motion plan. Accordingly, therobotic system 100 can continue executing the sequenced actions (i.e.,following the grip and/or the initial lift) in the base motion plan byoperating the actuation devices 212 and/or the transport motor 214 ofFIG. 2 according to the remaining sequence of commands and/or settings.For example, the robotic system 100 can transfer (e.g., verticallyand/or horizontally) and/or reorient the target package 112 according tothe base motion plan.

While executing the base motion plan, the robotic system 100 can trackthe current location and/or the current orientation of the targetpackage 112. The robotic system 100 can track the current locationaccording to outputs from the position sensors 224 of FIG. 2 to locateone or more portions of the robotic arm and/or the end-effector. In someembodiments, the robotic system 100 can track the current location byprocessing the outputs of the position sensors 224 with acomputer-generated model, a process, an equation, a position map, or acombination thereof. Accordingly, the robotic system 100 can combine thepositions or orientations of the joints and the structural members andfurther map the positions to the grid to calculate and track the currentlocation 424. In some embodiments, the robotic system 100 can includemultiple beacon sources. The robotic system 100 can measure the beaconsignals at one or more locations in the robotic arm and/or theend-effector and calculate separation distances between the signalsources and the measured location using the measurements (e.g., signalstrength, time stamp or propagation delay, and/or phase shift). Therobotic system 100 can map the separation distances to known locationsof the signal sources and calculate the current location of thesignal-receiving location as the location where the mapped separationdistances overlap.

At decision block 724, the robotic system 100 can determine whether thebase plan has been fully executed to the end. For example, the roboticsystem 100 can determine whether all of the actions (e.g., the commandsand/or the settings) in the base motion plan 422 have been completed.Also, the robotic system 100 can determine that the base motion plan isfinished when the current location matches the task location 116. Whenthe robotic system 100 has finished executing the base plan, the roboticsystem 100 can reinitiate the process by imaging the pickup/task areas(block 702) and/or identifying another item in the pickup area as thetarget object (block 704) as described above.

Otherwise, at block 726, the robotic system 100 can measure the grip(i.e., by determining the contact/force measurements) during transfer ofthe target package 112. In other words, the robotic system 100 candetermine the contact/force measurements while executing the base motionplan. In some embodiments, the robotic system 100 can determine thecontact/force measurements according to a sampling frequency or atpredetermined times. In some embodiments, the robotic system 100 candetermine the contact/force measurements before and/or after executing apredetermined number of commands or settings with the actuation devices212. For example, the robotic system 100 can sample the contact sensors226 after or during a specific category of maneuvers, such as for liftsor rotations. Also, for example, the robotic system 100 can sample thecontact sensors 226 when a direction and/or a magnitude of anaccelerometer output matches or exceeds a predetermined threshold thatrepresents a sudden or fast movement. The robotic system 100 candetermine the contact/force measurements using one or more processesdescribed above (e.g., for block 710).

In some embodiments, the robotic system 100 can determine theorientation of the gripper and/or the target package 112 and adjust thecontact measure accordingly. The robotic system 100 can adjust thecontact measure based on the orientation to account for a directionalrelationship between a sensing direction for the contact sensor andgravitational force applied to the target object according to theorientation. For example, the robotic system 100 can calculate an anglebetween the sensing direction and a reference direction (e.g., “down” orthe direction of the gravitational force) according to the orientation.The robotic system 100 can scale or multiply the contact/forcemeasurement according to a factor and/or a sign that corresponds to thecalculated angle.

At decision block 728, the robotic system 100 can compare the measuredgrip to a threshold (e.g., a transfer grip threshold). In someembodiments, the transfer grip threshold can be less than or equal tothe initial grip threshold associated with evaluating an initial (e.g.,before transferring) grip on the target package 112. Accordingly, therobotic system 100 can enforce a stricter rule for evaluating the gripbefore initiating transfer of the target package 112. The thresholdrequirement for the grip can be higher initially since contactsufficient for picking up the target package 112 is likely to besufficient for transferring the target package 112.

When the measured grip satisfies (e.g., is not less than) the thresholdand the correct packages are gripped (e.g., determined based on theimage data from the vision sensor device 143), the robotic system 100can continue executing the base plan as illustrated at block 722 anddescribed above. When the measured grip fails to satisfy (e.g., is lessthan) the threshold or the correct packages are not gripped, the roboticsystem 100 can deviate from the base motion plan and execute one or moreresponsive actions as illustrated at block 530. When the measured gripis insufficient in light of the threshold, the robotic system 100 canoperate the robotic arm 139, the end-effector, or a combination thereofaccording to commands and/or settings not included in the base motionplan. In some embodiments, the robotic system 100 can execute differentcommands and/or settings based on the current location.

For illustrative purposes, the response actions will be described usinga controlled drop. However, it is understood that the robotic system 100can execute other actions, such as by stopping execution of the basemotion plan as illustrated at block 716 and/or by soliciting operatorinput as illustrated at block 718.

The controlled drop includes one or more actions for placing the targetpackage 112 in one of the drop areas (e.g., instead of the task location116) in a controlled manner (i.e., based on lowering and/or releasingthe target package 112 and not as a result of a complete grip failure).In executing the controlled drop, the robotic system 100 can dynamically(i.e., in real time and/or while executing the base motion plan)calculate different locations, maneuvers or paths, and/or actuationdevice commands or settings according to the current location. In someembodiments, end effector 140 can be configured for a grip releaseoperation for multiple instances of the target package 112. For example,in some embodiments, the end effector 140 can be configured forsimultaneously or sequentially performing the grip release operation byselectively disengage the vacuum regions 117 as necessary to releaseeach instance of the target package 112 accordingly. The robotic system100 can select whether to simultaneously or sequentially release objectsand the order or release based on the position of the retained objects,object arrangement at the drop area, etc.

At block 762, the robotic system 100 can calculate the adjusted droplocation and/or an associated pose for placing the target package 112.In calculating the adjusted drop location, the robotic system 100 canidentify the drop area (e.g., the source drop area, the destination droparea, or the transit drop area) nearest to and/or ahead (e.g., betweenthe current location and the task location) of the current location.Also, when the current location is between (i.e., not within) the dropareas, the robotic system 100 can calculate distances to the drop areas(e.g., distances to representative reference locations for the dropareas). Accordingly, the robotic system 100 can identify the drop areathat is nearest to the current location and/or ahead of the currentlocation. Based on the identified drop area, the robotic system 100 cancalculate a location therein as the adjusted drop location. In someembodiments, the robotic system 100 can calculate the adjusted droplocation based on selecting a location according to a predeterminedorder (e.g., left to right, bottom to top, and/or front to back relativeto a reference location).

In some embodiments, the robotic system 100 can calculate distances fromthe current location to open spaces (e.g., as identified in block 704and/or tracked according to ongoing placements of objects) within thedrop areas. The robotic system 100 can select the open space that isahead of the current location and/or nearest to the current location 424as the adjusted drop location.

In some embodiments, prior to selecting the drop area and/or the openspace, the robotic system 100 can use a predetermined process and/orequation to translate the contact/force measure to a maximum transferdistance. For example, the predetermined process and/or equation canestimate based on various values of the contact measure a correspondingmaximum transfer distance and/or a duration before a complete gripfailure. Accordingly, the robotic system 100 can filter out theavailable drop areas and/or the open spaces that are farther than themaximum transfer distance from the current location. In someembodiments, when the robotic system 100 fails to identify availabledrop areas and/or open spaces (e.g., when the accessible drop areas arefull), the robotic system 100 can stop executing the base motion plan,as illustrated at block 716, and/or solicit operator input, asillustrated at block 718.

At block 766, the robotic system 100 can calculate the adjusted motionplan for transferring the target package 112 from the current locationto the adjusted drop location. The robotic system 100 can calculate theadjusted motion plan in a way similar to that described above for block506.

At block 768, the robotic system 100 can execute the adjusted motionplan in addition to and/or instead of the base motion plan. For example,the robotic system 100 can operate the actuation devices 212 accordingto the sequence of commands or settings or combination thereof, therebymaneuvering the robotic arm 139 and/or the end-effector to cause thetarget package 112 to move according to the path.

In some embodiments, the robotic system 100 can pause execution of thebase motion plan and execute the adjusted motion plan. Once the targetpackage 112 is placed at the adjusted drop location based on executingthe adjusted motion plan (i.e., completing execution of the controlleddrop), in some embodiments, the robotic system 100 can attempt to regripthe target package 112 as described above for block 720 and then measurethe established grip as described above for block 710. In someembodiments, the robotic system 100 can attempt to regrip the targetpackage 112 up to an iteration limit as described above. If the contactmeasure satisfies the initial grip threshold, the robotic system 100 canreverse the adjusted motion plan (e.g., return to the pausedpoint/location) and continue executing the remaining portions of thepaused base motion plan. In some embodiments, the robotic system 100 canupdate and recalculate the adjusted motion plan from the currentlocation 424 (after regripping) to the task location 116 and execute theadjusted motion plan to finish executing the task.

In some embodiments, the robotic system 100 can update an area log(e.g., a record of open spaces and/or placed objects) for the accesseddrop area to reflect the placed target package 112. For example, therobotic system 100 can regenerate the imaging results for thecorresponding drop area. In some embodiments, the robotic system 100 cancancel the remaining actions of the base motion plan after executing thecontrolled drop and placing the target package 112 at the adjusted droplocation. In one or more embodiments, the transit drop area can includea pallet or a bin placed on top of one of the transport units 106 ofFIG. 1. At a designated time (e.g., when the pallet/bin is full and/orwhen the incoming pallet/bin is delayed), the corresponding transportunit can go from the drop area to the pickup area. Accordingly, therobotic system 100 can reimplement the method 500, thereby reidentifyingthe dropped items as the target package 112 and transferring them to thecorresponding task location 116.

Once the target package 112 has been placed at the adjusted droplocation, the robotic system 100 can repeat the method 700 for a newtarget object. For example, the robotic system 100 can determine thenext object in the pickup area as the target package 112, calculate anew base motion plan to transfer the new target object, etc.

In some embodiments, the robotic system 100 can include a feedbackmechanism that updates the path calculating mechanism based on thecontact measure 312. For example, as the robotic system 100 implementsthe actions to regrip the target package 112 with adjusted positions(e.g., as described above for block 720), the robotic system 100 canstore the position of the end-effector that produced the contact/forcemeasurements that satisfied the threshold (e.g., as described above forblock 712). The robotic system 100 can store the position in associationwith the target package 112. The robotic system 100 can analyze thestored positions (e.g., using a running window for analyzing a recentset of actions) for gripping the target package 112 when the number ofgrip failures and/or successful regrip actions reach a threshold. When apredetermined number of regrip actions occur for a specific object, therobotic system 100 can update the motion planning mechanism to place thegripper at a new position (e.g., position corresponding to the highestnumber of successes) relative to the target package 112.

Based on the operations represented in block 710 and/or block 726 therobotic system 100 (via, e.g., the processors 202) can track a progressof executing the base motion plan. In some embodiments, the roboticsystem 100 can track the progress according to horizontal transfer ofthe target package(s) 112. The robotic system 100 can track the progressbased on measuring the established grip (block 710) before initiatingthe horizontal transfer and based on measuring the grip during transfer(block 726) after initiating the horizontal transfer. Accordingly, therobotic system 100 can selectively generate a new set (i.e., differentfrom the base motion plan) of actuator commands, actuator settings, or acombination thereof based on the progress as described above.

In other embodiments, for example, the robotic system 100 can track theprogress based on tracking the commands, the settings, or a combinationthereof that has been communicated to and/or implemented by theactuation devices 212. Based on the progress, the robotic system 100 canselectively generate the new set of actuator commands, actuatorsettings, or a combination thereof to execute the regrip response actionand/or the controlled drop response action. For example, when theprogress is before any horizontal transfer of the target package 112,the robotic system 100 can select the initial grip threshold and executethe operations represented in blocks 712 (via, e.g., function calls orjump instructions) and onward. Also, when the progress is after thehorizontal transfer of the target package 112, the robotic system 100can select the transfer grip threshold and execute the operationsrepresented in blocks 728 (via, e.g., function calls or jumpinstructions) and onward.

Implementing granular control/manipulation of the target package 112(i.e., choosing to implement the base motion plan or deviate from it)according to the contact/force measurement and vision-based monitoring,via the imaging data from the vision sensor device 143, providesimproved efficiency, speed, and accuracy for transferring the objects.For example, regripping the target packages 112 when the contact measureis below the initial grip threshold or the packages 112 are improperlypositioned decreases the likelihood of grip failure occurring duringtransfer, which decreases the number of objects lost or unintentionallydropped during transfer. The vacuum regions and vacuum levels can beadjusted to maintain the desired grip further enhances handling of thepackages 112. Moreover, each lost object requires human interaction tocorrect the outcome (e.g., move the lost object out of the motion pathfor subsequent tasks, inspect the lost object for damages, and/orcomplete the task for the lost object). Thus, reducing the number oflost objects reduces the human effort necessary to implement the tasksand/or the overall operation.

FIGS. 18-21 illustrate stages of robotically gripping and transportingobjects according to the method 490 of FIG. 16 or method 700 of FIG. 17in accordance with one or more embodiments of the present disclosure.FIG. 18 shows the gripper assembly 141 located above a stack of objects.The robotic arm 139 can positioned the gripper assembly 141 directlyabove targeted objects. A controller can analyze image data from thevision sensor device 143 to identify, for example, the target objects812 a, 812 b, as discussed at block 704 of FIG. 17. A plan (e.g., pickupor base plan) can be generated based on collected image data. The plancan be generated based on (a) a carrying capability of the gripperassembly 141 and/or (b) a configuration of target objects.

FIG. 19 shows the lower surface of the gripper assembly 141 overlayingthe target objects 812 a, 812 b and a large non-targeted object 818.Output from the vision sensor device 143 can be analyzed to confirm theposition of the gripper assembly 141 relative to the targeted objects.Based on the position of the objects 812 a, 812 b, the vacuum regions117 a, 117 b are identified for drawing a vacuum. In some embodiments,readings from the force sensor 203 are used to confirm the gripperassembly 141 has contacted the upper surfaces of a stack 814 prior toand/or after gripping target objects 812 a, 812 b.

FIG. 20 shows air being sucked into the vacuum regions 117 a, 117 b, asindicated by arrows, to hold the target objects 812 a, 812 b against thegripper assembly 141 without drawing a vacuum (or a substantial vacuum)at the other vacuum region 117 c. The vacuum level can be increased ordecreased to increase or decrease the compression of the compliantpanel(s) 412 (one identified). The vacuum grip can be evaluated asdiscussed in connection with block 710 of FIG. 17.

FIG. 21 shows the raised gripper assembly 141 securely holding thetarget objects 812 a, 812 b. The vision sensor device 143 can be used tomonitor the positions of the target objects 812 a, 812 b. Additionallyor alternatively, the force detector assembly 205 can be used todetermine information about the load, such as the positions and weightof the target objects 812 a, 812 b. The vacuum regions 117 a, 117 b cancontinue to suck in air to securely hold the targeted objects 812 a, 812b. The vacuum grip can be monitored during transfer, as discussed atblock 726 of FIG. 17. The applied vacuum can be stopped or reduced torelease the objects 812 a, 812 b. This process can be repeated totransfer each of the objects in the stack.

CONCLUSION

The above Detailed Description of examples of the disclosed technologyis not intended to be exhaustive or to limit the disclosed technology tothe precise form disclosed above. While specific examples for thedisclosed technology are described above for illustrative purposes,various equivalent modifications are possible within the scope of thedisclosed technology, as those skilled in the relevant art willrecognize. For example, while processes or blocks are presented in agiven order, alternative implementations may perform routines havingsteps, or employ systems having blocks, in a different order, and someprocesses or blocks may be deleted, moved, added, subdivided, combined,and/or modified to provide alternative or sub-combinations. Each ofthese processes or blocks may be implemented in a variety of differentways. Also, while processes or blocks are at times shown as beingperformed in series, these processes or blocks may instead be performedor implemented in parallel, or may be performed at different times.Further, any specific numbers noted herein are only examples;alternative implementations may employ differing values or ranges.

These and other changes can be made to the disclosed technology in lightof the above Detailed Description. While the Detailed Descriptiondescribes certain examples of the disclosed technology as well as thebest mode contemplated, the disclosed technology can be practiced inmany ways, no matter how detailed the above description appears in text.Details of the system may vary considerably in its specificimplementation, while still being encompassed by the technologydisclosed herein. As noted above, particular terminology used whendescribing certain features or aspects of the disclosed technologyshould not be taken to imply that the terminology is being redefinedherein to be restricted to any specific characteristics, features, oraspects of the disclosed technology with which that terminology isassociated. Accordingly, the invention is not limited, except as by theappended claims. In general, the terms used in the following claimsshould not be construed to limit the disclosed technology to thespecific examples disclosed in the specification, unless the aboveDetailed Description section explicitly defines such terms.

Although certain aspects of the invention are presented below in certainclaim forms, the applicant contemplates the various aspects of theinvention in any number of claim forms. Accordingly, the applicantreserves the right to pursue additional claims after filing thisapplication to pursue such additional claim forms, in either thisapplication or in a continuing application.

What is claimed is:
 1. A method for operating a transport robot thatincludes a multi-gripper assembly, the method comprising: receivingimages captured by a vision sensor device attached to the multi-gripperassembly, wherein the captured images are representative of a group ofobjects within a gripping zone of the multi-gripper assembly;identifying one or more target objects in the group based on thereceived images; selecting at least one of a plurality of addressablevacuum regions of the multi-gripper assembly based on the one or moretarget objects; generating commands and/or settings to grip the one ormore target objects using the selected at least one of the plurality ofaddressable vacuum regions; and robotically move the multi-gripperassembly to transport the gripped one or more target objects away fromother objects in the group.
 2. The method of claim 1, wherein thereceived images include lidar data, radar data, video, still images, orcombinations thereof.
 3. The method of claim 1, further comprisingcausing a vacuum to be drawn through suction elements of the pluralityof addressable vacuum regions positioned to hold the one or more targetobjects via a vacuum grip.
 4. The method of claim 1, wherein identifyingthe one or more target objects includes mapping at least a portion of apickup region using the received images, wherein the group is at thepickup region; and analyzing the mapping to determine which of theobjects at the pickup region are capable of being transported togetherby the multi-gripper assembly.
 5. The method of claim 1, furthercomprising: determining a set of the objects in the group capable ofbeing simultaneously lifted and carried by the multi-gripper assembly;and wherein identifying the one or more target objects includesselecting one or more objects from the set as the one or more targetobjects.
 6. The method of claim 1, further comprising: determiningwhether at least one object in the group is proximate to or at thegripping zone, and in response to determining the at least one object inthe group is proximate to or at the gripping zone, causing the visionsensor device to capture image data of the at least one object in thegroup, and determining a position of the at least one object in thegroup.
 7. The method of claim 1, further comprising: generating a pickupplan based on the received images; transporting, using the multi-gripperassembly, the objects in the group based on the pickup plan; andmonitoring, using the vision sensor device, the transport of the objectsin the group.
 8. The method of claim 1, further comprising: generatingfirst commands for causing the multi-gripper assembly to a pickuplocation based on positions of the identified one or more targetobjects, and generating second commands for causing a vacuum to be drawnvia the selected at least one of the plurality of addressable vacuumregions overlaying the identified one or more target objects withoutdrawing a vacuum through other ones of the addressable vacuum regionsthat overlay non-targeted objects, if any, in the group.
 9. A robotictransport system comprising: a robotic apparatus; an end effectorcoupled to the robotic apparatus and including a multi-gripper assemblyincluding a plurality of addressable vacuum regions, and a manifoldassembly configured to fluidically couple each of the addressable vacuumregions to at least one vacuum line such that each addressable vacuumregion is capable of independently providing suction to hold a targetobject while the robotic apparatus moves the multi-gripper assemblycarrying the target object; and a vision sensor device positioned tocapture image data representative of the target object being carried bythe multi-gripper assembly; and a controller programmed to causeselected ones of the addressable vacuum regions to hold the targetobject based on the captured image date, wherein each of the addressablevacuum regions includes a plurality of suction elements configured forvacuum gripping.
 10. An end effector comprising: a multi-gripperassembly including a plurality of addressable vacuum regions defining avacuum gripping zone, and a manifold assembly configured to fluidicallycouple each of the addressable vacuum regions to at least one vacuumline such that each addressable vacuum region is capable ofindependently providing suction to hold a target object while a roboticapparatus moves the multi-gripper assembly carrying the target object;and a vision sensor device carried by the multi-gripper assembly andconfigured to capture image data representative of at least a portion ofthe vacuum gripping zone.
 11. The end effector of claim 10, wherein themulti-gripper assembly includes a plurality of suction elementsfluidically coupled to the manifold assembly, and a panel through whichthe plurality of suction elements extend such that, when air is drawninto the suction elements, the target object is pulled against the panelto increase the vacuum gripping force provided by the multi-gripperassembly.
 12. The end effector of claim 11, wherein the captured imagedata is representative of the target object being carried by themulti-gripper assembly, and the vision sensor device is positioned todetect a presence of one or more objects, if any, held by themulti-gripper assembly against the panel, and the captured image dataincludes lidar data, radar data, video, still images, or combinationsthereof.
 13. The end effector of claim 10, wherein the vision sensordevice is positioned laterally of the vacuum gripping zone such that thevacuum gripping zone is unobstructed from below when a grippinginterface of the multi-gripper assembly is at a substantially horizontalorientation.
 14. The end effector of claim 10, wherein the vision sensordevice is configured to output the captured image data for identifyingone or more target objects in a group, and the multi-gripper assembly isconfigured to grip and carry the identified one or more target objectsaway from other objects in the group.
 15. The end effector of claim 10,wherein the captured image data includes data that enablesidentification of multiple objects spaced apart from one another. 16.The end effector of claim 10, wherein the multi-gripper assembly isconfigured to hold the target object using selected ones of theaddressable vacuum regions based on the captured image date, whereineach of the addressable vacuum regions includes a plurality of suctionelements configured for vacuum gripping.
 17. The end effector of claim10, wherein the end effector is configured to generate a pressuredifferential at region of the vacuum gripping zone corresponding to thetarget object to selectively grip the target object.
 18. The endeffector of claim 10, wherein the vision sensor device has afield-of-view extending across the vacuum gripping zone to capture imagedata representative of the vacuum gripping zone.
 19. The end effector ofclaim 10, wherein the vision sensor device is configured to captureimage data representing gaps between objects positioned directly belowthe multi-gripper assembly.
 20. The end effector of claim 10, whereinthe end effector is configured to be fluidically coupled to an externalvacuum source such that each of the addressable vacuum regions isfluidically coupled to the external vacuum source via the at least onevacuum line.